JPS62149403A - Manufacturing method of laminated resin foam and mold for resin foam processing - Google Patents

Abstract

PURPOSE:To obtain a laminated resin foamed, body in which at least two foamed resin layers having different characteristics are integrally joined, by integral foam processing by a method wherein a foam processing mold, on the wall of which a weir plate is protrusively provided, is used so that resin foaming liquid to produce soft foamed body is poured in a space on one side of the dam plate and resin foaming liquid to produce hard foamed body is poured in a space on the other side of the weir plate so as to expand and harden both the resin foams. CONSTITUTION:In a mold 1, a weir plate 4 is protrusively provided so as to extend from the corner of the mold in order to partition some portion of a mold space by the weir plate 4 into spaces A and B. Under the state that the mold 1 is held in an inclined posture, resin foaming liquid 5 to produce soft foam and resin foaming liquid 6 to produce hard foam are respectively poured in the spaces A and B so as to expand and fill the mold space in order to foam and harden both the foaming liquids 5 and 6. Both the foaming liquids 5 and 6 start to foam and expand along the weir plate 4 and, after expanding beyond the top of the weir plate 4, are joined into an integral body in the form that soft layer 8 and hard layer 9 press against each other with the processing of expansion so as to form a laminated resin foamed body 7, which consists of both soft and hard layers and has a small gap.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing an 8I-layer resin foam, such as a pad for an automobile seat, and a method for producing an 8I-layer resin foam, such as a pad for an automobile seat seating area, and a method for producing an 8I-layer resin foam, such as a padding for an automobile seat seating area. This is a guide to molds for resin foam processing.

Car seats are required to have the performance of providing good static comfort to the occupants, and have a structure that allows the occupants to maintain their naturally desired posture with the least amount of muscle activity, and which is designed to reduce blood flow. It must be done horizontally without exhibiting a body pressure distribution that obstructs circulation and promotes fatigue.Furthermore, the level of fatigue caused by continuous sitting is also an issue.
Fatigue can be reduced by using a hard pad instead of a soft one with excessive cushion suspension at the jf portion.

FIG. 1 shows, as an example, a four-seat portion of an automobile seat as a schematic vertical view, in which a foamed polyurethane pad 03 stretched over a frame 01 is fixed, and the entire upper surface is covered with a skin 04. However, in recent years, a structure in which the zigzag spring 02 is omitted and only a foamed polyurethane pad 03 is provided as shown in FIG. 2 has been adopted.

However, when the pad 03 is made of a single layer of polyurethane foam, it is difficult to satisfy the various characteristics required for the comfort of the seating area. have flexibility,
Either a relatively soft foam and a hard foam are bonded with an adhesive and laminated together, or a foamed one in which both the hard and soft layers are laminated together is used.

However, with the former method, depending on the type of adhesive used, the foam may melt at the bonding interface and turn into a dense, hard structure, which may only have a negative effect on the wearing comfort. However, there is a problem that the joining work is troublesome and productivity is hindered.

In addition, with the method of a small person, when a resin foaming liquid that obtains both hard and soft layers is injected into a mold and foamed, it is difficult to properly determine the interface position 16 of both hard and soft layers and the thickness of each layer. There is a problem that the quality fluctuates greatly, and when slabs etc. are laminated and foamed together, the foaming liquid impregnates the slabs etc. and forms a hardened layer, which has a negative effect on the comfort of wearing.

The present invention was devised against this technical background, and its purpose is to form a structure in which at least two foamed resin layers having different properties are integrated. The point is to obtain a bonded laminated resin foam by integral foaming processing while suppressing variations in the layer thickness ratio of each layer between products as much as possible.

This purpose is to use a mold for foam processing with a weir plate protruding from the mold wall, inject a resin foaming liquid containing 1 q of soft foam into the space on one side of the weir plate, and to This is achieved by injecting into the side space a resin foaming liquid that produces a foam that is harder than the soft foam, and then foaming and hardening the resin foam. The resin foaming liquid includes a liquid foaming stock solution and a foamed liquid.

FIG. 3 shows a conceptual perspective view of a mold 1 for resin foam processing as an example used in the present invention. This mold 1
In the mold, a weir plate 4 is provided protrudingly extending from the corner where the mold walls 2.3 intersect, and a part of the mold space is divided into spaces 8 by the weir plate 4. There is.

To carry out the foaming process using gold 1, as shown in FIG. 4, the mold 1 is maintained in an inclined position, and the soft foam is placed in spaces Δ and B, respectively. 5. Resin foaming liquid (hereinafter simply referred to as foaming liquid). A resin foaming solution that produces a foam that is harder than the soft foam described above.

6 (simply referred to as foaming liquid) is injected and foamed to fill the mold space, and then foaming liquid 5.6 is foamed.

Let it harden. Each foaming liquid 5.6 has +1. Foaming and expansion begins along the plate 4, and after passing the tip of the weir plate 4, the soft Li1 layer 8 and vJ! While the M layer (meaning that it is harder than the soft layer 8) 9 is joined together in a form that fits each other, the expansion causes the hard layer and the soft layer 7 to be molded in one line. (See Figure 5). The thickness of each layer of the soft layer 8 and the hard layer 9 can be determined by changing the inclination angle θ of the weir plate 4 with respect to the mold wall 3, the length of the weir plate 4, or ω of each foaming liquid 5.6.
If such adjustments can be made and such conditions are kept constant, a product with less variation in layer thickness ratio can be stably obtained.

In addition, it is possible to change the layer J9 and the interface state between the soft layer 8 and the hard layer 9 by changing the injection product of the foaming liquids 5 and 6, the injection location, the distribution of the injection product, and the foaming timing. .

1''Ll Hereinafter, an example of molding a pad 25 used for a seating portion of an automobile seat by the method of the present invention will be explained with reference to FIGS. 6 to 9.

The mold 20 has a weir plate 23 similar to the weir plate 4 that is applied to the mold 1.
The main body 21 has spiral portions 22 formed on both sides thereof, and a retaining wall 24 that closes the main body 21 so as to be tiltable. Heat mold 20 in oven 1
-MA 1111 Q to l-+-+ IJ 7-
1ffi K-LiQ/7%μ;W: llTlQ
'n llTl A Resin foaming liquid 29 to obtain a soft foam is injected into the space B on the other side, and vf is compared to the soft foam. Resin foaming liquid to obtain trade foam 3
0 is injected, the lid wall 24 is closed, and each of the foaming liquids 29 and 30 is foamed and hardened, so that the space C including the space A and facing the base wall of the main body 21 is filled with the soft layer 26. A pad 25, which is an integrally molded product, is formed in a portion filled with a hard V'i (meaning that it is harder than the soft layer 26) 27. The pad 25 has a soft layer 26 on the upper layer of the portion that supports both thighs of the occupant, and the other portions including the raised side sides and rear side formed by the grooved portion 22 are made of a hard layer 27. A small 12mm is formed by the weir plate 23 between the soft layer 26 and the hard layer 27 in the sprout part.
! ] A septum 28 is present.

In the pad 25 having such a structure, the entire bottom layer, both sides of the raised shape, and the rear side are formed of the hard layer 27, so it has excellent shape retention characteristics against changes in applied force, and can be easily moved in the left and right directions. The occupant's body can be stably supported against the rear inertia force. In addition, when both plate portions of the passenger are supported by the soft layer 26, the contact pressure is likely to be high at the front side of the seat, and the soft layer 26 and the hard τ1 layer 2
Although there is a small space 28 at the interface between the seats 7 and 7, the contact pressure of the seat surface against both plate parts is made uniform, and the seating comfort is extremely good.

Furthermore, since the soft layer 26 and the hard layer 27 of the pad 25 are integrally bonded to the foamed a4, there is no adverse effect from the adhesive, and properties (1) of both layers 26 and 27 are not impaired. do not have.

In the above embodiment, the substantially rectangular weir plate 23 was provided protruding from the main body 21 of the mold 20, but in addition, the weir plate 3 having the shape shown in FIGS. 9 to 11 may be used. , 32.33 may also be used.

The weir plate 31 shown in FIG. 10 has a semicircular shape and is made of resin with 1q of soft foam. 21 liquid 29, a resin foaming liquid 30 that produces 1 g of a foam that is harder than the soft foam (meaning that it is harder than the two resin foam liquids that yield the soft foam) is shown in the arrow. As such, the hard resin foaming liquid 30 expands radially and is integrally joined with the soft resin foaming liquid 29 at the part 11a that enters the groove-shaped portion 22. Therefore, the bonding interface between both layers can be made sufficiently large.

The weir plate 32 shown in FIG. 11 has a hybrid shape of the weir plate 23 and the weir plate 31, and includes a resin foaming liquid 29 for producing a soft foam and a resin foaming solution for producing a foam that is harder than the soft foam. The liquid 30 (meaning that it is harder than the resin foaming liquid 29 for obtaining a soft foam) expands as shown by the arrow, and the groove-shaped portion 2
The resin foaming liquid 30 is guided by the weir plate 32 to both end positions to merge the soft foam with the resin foaming liquid 29. It expands and goes to jW rows.

The weir plate 33 shown in FIG. 12 has a shape in which the semicircular part of the weir plate 32 is greatly elongated, and the pad molded with this mold has a large expansion in the small interval part, but is hard and The thickness of both soft layers can be adjusted with high precision, and quality differences between products can be sufficiently reduced.

As is clear from the above explanation, a foam processing mold with a weir plate protruding from the mold wall is used, and a soft foam is applied to the space on one side of the weir plate.
5. Injecting a resin foaming solution to obtain a foam, and also injecting a resin foaming solution to obtain a foam that is harder than the soft foam into the space on the other side of the weir plate. A method for producing a laminated resin foam characterized by foaming and curing, and a mold for resin foam processing for carrying out this method have been proposed.

According to the above-mentioned manufacturing method using a mold having a weir plate on the mold wall, a laminated resin foam in which 1q of 'i's are integrated into both hard and soft foamed resins can be produced by foam processing alone without post-processing. By using 11 temporary, it becomes easy to adjust the layer thickness ratio of both hard and soft layers, and it is possible to produce a laminated resin foam of stable quality. .

[Brief explanation of drawings]

Figures 1 and 2 are a top view of the external part of a known automatic middle seat, and Figure 3 is a conceptual perspective view of a foam processing scheme for carrying out the present invention. Figure 4 is a longitudinal 1f Ji side view of the resin foaming liquid injected into the mold, and Figure 5 is the resin foaming;
7)? A side view of a single-layer resin foam, FIG. 8 is a sectional view taken along the line ■-■, FIG. 9 is a partially cutaway perspective view of pad No. 11a, and FIGS. 10 to 1.
FIG. 2 is a perspective view of a main part of a resin foaming mold according to a modified example. 1... Gold τ! , 2...Mold wall, 3...Mold wall, 4...
・Weir plate, 5... Soft foam 1! #ru resin foaming liquid, 6
... Resin foaming liquid for obtaining a foam that is harder than a soft foam, 7... Laminated resin foam, 8... Soft layer, 9...
・Hard layer, 10... Small interval part, 20... Mold, 21
... Main body, 22 ... Spiral part, 23 ... Jl plate,
24... Lid wall, 25... Pad, 26... Soft layer, 27... Hard layer, 28... Small interval part, 29...
Resin foaming liquid to obtain soft foam, 30... hard foam compared to soft foam j! Resin foaming liquid.

Claims (2)

[Claims] (1) In a method for manufacturing a laminated resin foam in which at least two foamed resin layers with different properties are joined together, a foam processing mold with a weir plate protruding from the mold wall is used, and one side of the weir plate is A resin foaming liquid to obtain a soft foam is injected into the side space, and a resin foaming liquid to obtain a foam that is harder than the soft foam is injected into the space on the other side of the weir plate. A method for producing a laminated resin foam, characterized by foaming and curing a resin foaming liquid. (2) A weir plate that allows resin foaming liquid to be injected in a separated state in a mold for resin foam processing to obtain a laminated resin foam in which at least two foamed resin layers with different properties are joined together. A mold for resin foam processing, characterized in that a part of the mold space is partitioned into at least two spaces by protruding from the mold wall.